Search Results (136)

The selection of grinding media significantly impacts the resulting mineral’s liberation degree and grinding quality; this is particularly impactful for granite pegmatite-type quartz. Accordingly, in this study, we investigate the effects of different grinding media on the breakage characteristics of muscovite granite pegmatite-type quartz, focusing also on quartz mineral flotation. An analysis of scanning electron microscope images reveals distinct fracture characteristics among different minerals. Notably, the fractal dimension of mineral fracture roughness in ball-milled products is larger compared to that of rod-milled products, which exhibit a smaller fractal dimension. This fractal dimension serves as a quantitative measure of the microscopic morphology of mineral fractures in the grinding products, establishing a relationship between the roughness of the fractures and the type of grinding medium used. Further analysis of particle size distribution and mineral dissociation indicates that the rod mill produces a higher yield of coarse fractions compared to both ceramic and steel balls, while the fine fraction yield is significantly lower than that of the rod mill and steel balls. Importantly, the rod mill enhances the dissociation degree of quartz, suggesting that it can improve the liberation of mineral monomers and increase the yield of qualified fractions during the grinding process while effectively reducing the phenomenon of overgrinding. Our flotation experiments demonstrate that the recovery rate of quartz using the rod mill is 2.59% and 5.07% higher than that achieved with the ball mill and ceramic mill, respectively. These findings provide theoretical support for the optimization of grinding media and enhancement of mineral flotation recovery. Full article

Purpose Maintaining the surface quality of ceramic restorations after clinical adjustments is critical for both aesthetic outcomes and long-term oral health, yet the optimal approach to restoring gloss and smoothness remains unclear. The purpose of this study is to investigate the effect of different surface finishing and grinding procedures on the surface gloss and roughness of three different monolithic lithium disilicate ceramics and one monolithic ultra-translucent zirconia ceramic. Materials and Methods A total of 104 specimens (1.5 × 12 × 14 mm) were prepared from four ceramic materials: LiSi CEREC Tessera (CT), GC Initial LiSi (LS), IPS e.max CAD (EC), and zirconia disc (KATANA UTML (KAT)). Each was divided into two subgroups based on surface finishing (mechanical polishing or glazing; n = 10). Gloss and surface roughness were measured using a glossmeter and a profilometer, respectively. One specimen per subgroup was analyzed under SEM at ×1000 magnification. Results Gloss and roughness values were analyzed with the two-way robust ANOVA test and multiple comparisons were made with Bonferroni correction. The significance level was set at p < 0.05. Mechanical polishing, glazing, and repolishing increased the gloss values of the materials, with the KAT group achieving the highest gloss in the repolishing groups. The lowest gloss values were observed in the grinding groups. Additionally, these surface treatments reduced the roughness of the surface of all the materials. Conclusions Surface finishing procedures significantly influenced the gloss and roughness of monolithic lithium disilicate and zirconia ceramics. Mechanical polishing systems performed similarly or better than glazing. However, selecting an appropriate polishing system for each material is essential. Full article

This study assessed the repair shear bond strength (SBS; MPa) and surface roughness (Ra; μm) of aged hybrid ceramic (Cerasmart270, GC) and nano-hybrid ceramic (Grandio Blocs, Voco) CAD/CAM blocks after different surface pretreatment methods. In this study, 2 mm thick Cerasmart270 and Grandio Blocs were cut into slabs (Isomet; n = 80 per group). Following aging for six months, the specimens in each CAD/CAM material were randomly divided into four groups (n: 20 each) according to the surface pretreatments: control (no pretreatment), Er:YAG laser, sandblasting, and bur grinding. A total of 10 specimens in each CAD/CAM material pretreatment group were used for Ra evaluation (Perthometer Mahr), while the other 10 were for SBS. After the application of a silane primer (G-Multi Primer, GC) and universal adhesive (G2-Bond, GC), composite build-ups (Filtek Z250; 3MESPE) were performed for the SBS evaluation. After storage in distilled water for 24 h, SBS was evaluated with a universal testing machine (Instron). SBS and Ra data were analyzed with two-way ANOVA and Tukey’s post hoc tests (p < 0.05). SBS was significantly affected by the surface pretreatment methods (p = 0.0001) and by the types of CAD/CAM material (p = 0.005). Bur grinding showed the highest SBS for both CAD/CAM materials, while the control groups yielded significantly lower SBS than bur grinding and sandblasting (p < 0.05). Er:YAG lasers did not significantly enhance the SBS compared to the control group. Sandblasting presented significantly higher SBS than lasers only in Grandio Blocs (p < 0.05). The surface pretreatment methods significantly influenced Ra (p = 0.0001); however, no significant interaction was found between the types of CAD/CAM material and the surface pretreatments (p > 0.05). Control groups exhibited, significantly, the lowest Ra for both materials (p = 0.0001), while no significant differences were observed between the other pretreatment methods. Bur grinding was identified as the most effective pretreatment method for repairing hybrid ceramic CAD/CAM materials. Full article

Rational waste management is crucial for the effective implementation of the circular economy (CE) and the achievement of Sustainable Development Goals (SDGs). Ceramic waste, which takes thousands of years to decompose in the natural environment, can be recycled into construction materials. This approach offers dual environmental benefits: reducing ceramic waste disposal and minimizing the exploitation of natural aggregate deposits. This study examines the recycling of sanitary ceramic waste, including items such as washbasins, toilet bowls, urinals, bidets, and bathtubs, into alternative aggregates for concrete mixtures. After grinding and separating the ceramic cullet into specific fractions, it becomes a viable substitute for natural aggregates. Concrete samples were tested with varying water-cement ratios (0.3 and 0.4) and recycled ceramic aggregate contents (15%, 30%, and 45%). These results were compared to those of samples made solely with natural aggregates. The samples underwent compressive strength tests to determine concrete class and were exposed to elevated temperatures (150 °C, 300 °C, 550 °C, and 750 °C). Additional analyses measured the secant modulus of elasticity and selected aggregate properties. The findings demonstrate that high-quality concrete can be produced while promoting circular economy principles by reducing waste and preserving natural resources. Full article

Boron Neutron Capture Therapy (BNCT) is a therapeutic approach used to treat malignancies that are difficult to localise and typically inoperable. This therapy involves two stages: the administration of the boron (¹⁰B) isotope, which selectively enters cancer cells without affecting healthy tissue, followed by irradiation of the tumour with a neutron beam. In this study, boron carbide (B₄C), a ceramic material with exceptional physical and chemical properties, was used as a nanoparticle platform for BNCT. The surface of the boron carbide nanoparticles was optimised by modifying them with compounds such as dextrin, dextran T70, sorbitol, lysine, and arginine. Boron carbide was synthesised directly from boron and carbon and then subjected to grinding, washing, and centrifugation. The unmodified and modified samples were analysed for their particle size, zeta potential, and toxicity against glioblastoma T98G cells. Additionally, FTIR spectroscopy confirmed the successful surface modifications. The results demonstrate that boron carbide, as a ceramic material, can be effectively functionalised with biocompatible compounds. Among the tested modifications, B₄C-dextrin and B₄C-dextran T70 exhibited the highest toxicity towards cancer cells, demonstrating the potential of ceramic platforms in biomedical applications. Full article

Silicon nitride (Si₃N₄) is used for high-speed rotating bearings in machine tools, aircraft, and turbo pumps due to its excellent material properties such as high-temperature strength, hardness, and fracture toughness. Grinding with fixed abrasives enables high shape accuracy and high efficiency in machining brittle materials. However, it is difficult to completely remove surface damage, which limits its use in products requiring a nano surface. These defects also result in reduced reliability and shortened lifespan. Magnetic-assisted polishing (MAP) is a technology that can achieve a fine surface by using a mixture of iron powder and abrasives, but it requires a lot of time due to the low material removal rate (MRR). Therefore, this study developed a hybrid processing technology using a metal-bonded grinding wheel and a slurry with hard abrasives for the high precision of silicon nitride ceramic ball bearings. Experiments were conducted in order to compare and analyze the surface roughness and material removal rate. Through MAP, using a grinding wheel with low grit (#325), high-efficiency machining performance was confirmed with a maximum material removal rate of 1.193 mg/min. In MAP, using a grinding wheel with high grit (#2000), a nano-level surface roughness of 6.5 nm Ra was achieved. Full article

This paper studies the structural parameters and electrophysical properties (dielectric and piezo electric, as well as currents of thermostimulated depolarization) of samples of composition 0.20BiScO₃·0.45PbTiO₃·0.35PbMg_1/3Nb_2/3O₃ (or in short 0.20BS·0.45PT·0.35PMN) obtained by ceramic and melt-hardening methods of synthesis. In the ceramic method, the samples were obtained from the starting oxides by two-stage firing. In the melt method, amorphous precursors were first obtained from heat-treated and non-heat-treated starting oxide mixtures by melting and subsequent quenching under sharply gradient temperature conditions. Samples were obtained after grinding, pressing, and thermal annealing of the synthesized precursors, and four types of samples differing in size and shape of the intermediate precursor particles (crystallites) were obtained. The X-ray phase analysis showed that the predominant phase in the studied samples is the perovskite phase; in both types of samples, up to 5 wt.% of impurity phase with pyrochlore structure was also present. The samples of 0.20BS·0.45PT·0.35PMN exhibit dielectric properties characteristic of relaxor ferroelectrics, and the polarized samples exhibit a pronounced piezo effect with a piezo modulus value of d₃₃~200 pC/N. A comparative analysis of the properties of the samples obtained by different methods has been carried out. The essential advantage of the melt method is that its use allows obtaining varieties of four kinds of ferroelectric relaxors and reduces the time of synthesis of samples by 2–3 times. Full article

Helical grinding is crucial for manufacturing small holes in hard-to-machine composite ceramics. This study introduces a geometric model of undeformed chips to analyze the cutting characteristics of abrasive grains on both the bottom and side edges of the tool. It reveals for the first time that the distribution of cutting grains—pure bottom-edge, pure side-edge, and mixed-edge—is influenced by the tool diameter and eccentricity. A novel calculation method for the distribution range (D_p) of pure bottom-edge grains is proposed, demonstrating that using a tool diameter at or below two-thirds of the target hole diameter effectively eliminates pure bottom-edge grains, improving chip evacuation, reducing chip adhesion, and optimizing cutting performance. Experimental validation on small holes in SiC_p/Al composites (65% volume fraction) confirmed these findings and provides practical guidance for optimizing cutting parameters and tool design. Full article

The surfaces of ceramic products are replete with numerous defects, such as those that appear during the diamond grinding of sintered SiAlON ceramics. The defective surface layer is the reason for the low effectiveness of TiZrN coatings under abrasive and fretting wear. An obvious solution is the removal of an up to 4-µm-thick surface layer containing the defects. It was proposed in the present study to etch the layer with fast argon atoms. At the atom energy of 5 keV and a 0.5 mA/cm² current density, the ions were converted into fast atoms and the sputtering rate for the SiAlON samples reached 20 μm/h. No defects were observed in the microstructures of coatings deposited after beam treatment for half an hour. The treatment reduced the volumetric abrasive wear by five times. The fretting wear was reduced by three to four times. Full article

Polycrystalline silicon carbide (SiC) is a highly valuable material with crucial applications across various industries. Despite its benefits, processing this brittle material efficiently and with high quality presents significant challenges. A thorough understanding of the mechanisms involved in processing and removing SiC is essential for optimizing its production. In this study, we investigated the sawing characteristics and material removal mechanisms of polycrystalline silicon carbide (SiC) ceramic using a diamond wire saw. Experiments were conducted with high wire speeds of 30 m/s and a maximum feed rate of 2.0 mm/min. The coarseness value (R_a) increased slightly with the feed rate. Changes in the diamond wire during the grinding process and their effects on the grinding surface were analyzed using scanning electron microscopy (SEM), laser confocal microscopy, and focused ion beam (FIB)-transmission electron microscopy (TEM). The findings provide insights into the grinding mechanisms. The presence of ductile grinding zones and brittle fracture areas on the ground surface reveals that external forces induce dislocation and amorphization within the grain structure, which are key factors in material removal during grinding. Full article

The machinability of steel is a crucial factor in manufacturing, influencing tool life, cutting forces, surface finish, and production costs. Traditional machinability assessments are labor-intensive and costly. This study presents a novel methodology to rapidly determine steel machinability using spark testing and convolutional neural networks (CNNs). We evaluated 45 steel samples, including various low-alloy and high-alloy steels, with most samples being calcium steels known for their superior machinability. Grinding experiments were conducted using a CNC machine with a ceramic grinding wheel under controlled conditions to ensure a constant cutting force. Spark images captured during grinding were analyzed using CNN models with the ResNet18 architecture to predict V15 values, which were measured using the standard ISO 3685 test. Our results demonstrate that the created prediction models achieved a mean absolute percentage error (MAPE) of 12.88%. While some samples exhibited high MAPE values, the method overall provided accurate machinability predictions. Compared to the standard ISO test, which takes several hours to complete, our method is significantly faster, taking only a few minutes. This study highlights the potential for a cost-effective and time-efficient alternative testing method, thereby supporting improved manufacturing processes. Full article

The aim of this study is to determine the effect of changes in the phase composition of Al₂O₃–Si₃N₄ ceramics that were obtained using the method of mechanochemical solid-phase grinding on their resistance to the process of long-term thermal exposure, accompanied by the processes of oxidation and softening. The relevance of this research consists of determining the influence of the phase composition of ceramics on the change in their strength and thermophysical parameters, on the basis of which, we can draw a conclusion about the optimal composition of composite ceramics that have great prospects in the field of fire-resistant, heat-resistant, or radiation-resistant structural materials. During this study, the dynamics of the changes in the phase transformations of the xAl₂O₃–(1−x)Si₃N₄ ceramics, with variations in the ratio of the components, initiated by the thermal annealing of the samples, was established. According to the assessment of the phase transformations with variations in the ratio of the components, it was found that thermal annealing in an air environment at an Al₂O₃ concentration in the order of 0.3–0.5 M leads to the formation of an orthorhombic Al₂(SiO₄)O phase and an elevation in its contribution at concentrations above 0.5 M, which causes a rise in the thermophysical parameters and resistance to high-temperature degradation. During the heat resistance tests, it was found that the formation of the composite ceramics with the Si₃N₄(SiO₂)/Al₂(SiO₄)O/Al₂O₃ phase composition results in an increase in the stability of their strength properties when exposed to thermally induced oxidation, which has a negative impact on their resistance to softening and a decrease in hardness. Moreover, the presence of the Al₂(SiO₄)O phase in the composition of the ceramics causes a slowdown in the processes of thermal oxidation of the Si₃N₄ phase under prolonged temperature exposure, alongside an increase in the degradation resistance of strength properties by more than 4–7 times, in comparison with the softening data established for single-component ceramics. Full article

Aluminium nitride (AlN) materials are widely used in heat-dissipation substrates and electronic device packages. However, the application of aluminium nitride ceramics is hindered by the obvious anisotropy and high brittleness of its crystals, leading to poor material surface integrity and high grinding force. With the rapid development of microelectronics, the requirements for the material’s dimensional accuracy, machining efficiency, and surface accuracy are increasing. Therefore, a new machining process is proposed, combining laser and ultrasonic vibration with grinding. The laser–ultrasonic-assisted grinding (LUAG) of aluminium nitride is simulated by molecular dynamics (MD). Meanwhile, the effects of different processing techniques on grinding force, stress distribution, matrix damage mechanism, and subsurface damage depth are systematically investigated and verified by experiments. The results show that laser–ultrasonic-assisted grinding produces 50% lower grinding forces compared to traditional grinding (TG). The microhardness of AlN can reach more than 1200 HV, and the coefficient of friction and wear is reduced by 42.6%. The dislocation lines of the AlN substrate under this process are short but interlaced, making the material prone to phase transformation. Moreover, the subsurface damage depth is low, realising the substrate’s material hardening and wear resistance. These studies not only enhance the comprehension of material build-up and stress damage under the synergistic impact of laser, ultrasonic, and abrasive processing but also indicate that the proposed method can facilitate and realise high-performance machining of aluminium nitride substrate surfaces. Full article

During industrial and laboratory processes involving material grinding, the grinding media endure prolonged high-collision and friction environments, resulting in substantial wear. Consequently, this study adopts the hot-pressing sintering technique in powder metallurgy to prepare SiC-reinforced Fe-based wear-resistant composite grinding media, aiming to increase wear performance. For this purpose, Fe with 10 wt% SiC powders were milled for the fabrication of the composite. Then, sintering was performed by hot press at 1100 °C in a furnace. Scanning electron microscopy (SEM) and X-ray diffraction were employed to investigate the microstructures and phase of SiC-reinforced Fe-based matrix composite. Subsequently, comparative performance evaluations of the newly developed grinding media and traditional chromium-based media were conducted in terms of wear rate and grinding efficiency. The wear resistance tests revealed that the SiC-reinforced composite media displayed significantly superior wear resistance across various abrasives compared to the chromium-containing alternatives. Specifically, the composite media achieved a wear rate reduction of 2.9 times against standard sand over 1 h, and 2.3 and 2.4 times against sandstone and iron slag, respectively. Moreover, extended grinding for 3 hours further enhanced these reductions to 3.1, 2.4, and 2.7 times, respectively. Additionally, efficiency assessments indicated that at a 1:1 material ratio, the composite media outperformed the chromium-containing media in grinding efficiency by 7.5%, 12.5%, and 10.3% for standard sand, sandstone, and iron slag, respectively. Further increasing the material ratio to 3:1 resulted in efficiency improvements of 7.4%, 17.5%, and 11.3%, correspondingly. Full article

SiC ceramics are typically hard and brittle materials. Serious surface/subsurface damage occurs during the grinding process due to the poor self-sharpening ability of monocrystalline diamond grits. Nevertheless, recent findings have demonstrated that porous diamond grits can achieve high-efficiency and low-damage machining. However, research on the removal mechanism of porous diamond grit while grinding SiC ceramic materials is still in the bottleneck stage. A discrete element simulation model of the porous diamond grit while grinding SiC ceramics was established to optimize the grinding parameters (e.g., grinding wheel speed, undeformed chip thickness) and pore parameters (e.g., cutting edge density) of the porous diamond grit. The influence of these above parameters on the removal and damage of SiC ceramics was explored from a microscopic perspective, comparing with monocrystalline diamond grit. The results show that porous diamond grits cause less damage to SiC ceramics and have better grinding performance than monocrystalline diamond grits. In addition, the optimal cutting edge density and undeformed chip thickness should be controlled at 1–3 and 1–2 um, respectively, and the grinding wheel speed should be greater than 80 m/s. The research results lay a scientific foundation for the efficient and low-damage grinding of hard and brittle materials represented by SiC ceramics, exhibiting theoretical significance and practical value. Full article